Water-repellent film-coated articles, water-repellent film-coating liquid composition and process for preparation of water-repellent film-coated articles

ABSTRACT

There are provided articles coated with high-performance water-repellent films with high hardness that can withstand outdoor use, which are water-repellent film-coated articles that comprise a substrate and a water-repellent film composed mainly of silicon oxide and having a water-repellent group coated on the surface of the substrate, and are characterized by containing at least one type of metal oxide selected from the group consisting of magnesium oxide, calcium oxide, strontium oxide and boron oxide, as well as a process for preparation of such water-repellent film-coated articles at a high rate of productivity and a coating liquid composition for preparation of such water-repellent film-coated articles.

TECHNICAL FIELD

[0001] The present invention relates to articles provided with awater-repellent film coating formed integrally with an primary oxidefilm on the surface of a substrate made of glass, ceramic, plastic,metal or the like, to a water-repellent film-coating composition and toa process for preparation of water-repellent film-coated articles.

BACKGROUND ART

[0002] The following techniques for formation of highly durablewater-repellent films on the surfaces of glass plates and othersubstrates at a high rate of productivity are known, which involveformation of a single film on a substrate using a mixed solution of aprimary layer component and a water-repellent component which gives aprimary layer and a water-repellent layer.

[0003] In Japanese Unexamined Patent Publication No. 4-338137 there isdisclosed a water-repellent glass characterized by applying of asolution comprising a mixture of a silicon alkoxide or a substitutedsilicon alkoxide wherein a portion of the alkoxyl groups are substitutedwith fluoroalkyl groups, an alcohol, water and an acid (or base) onto aglass substrate surface and sintering.

[0004] In Japanese Unexamined Patent Publication No. 8-239653 there aredisclosed water-repellent articles treated with a composition comprisinga mixture of a perfluoroalkylalkylsilane and a thoroughly hydrolyzablesilane (for example, tetrachlorosilane) dissolved in a solvent,preferably a non-aqueous solvent.

[0005] In Japanese Unexamined Patent Publication No. 11-71682 there aredisclosed water-repellent film-coated articles treated with acomposition comprising a chlorosilyl group-containing compound and afluoroalkyl group-containing silane compound dissolved in analcohol-based solvent.

[0006] In these conventional techniques, the final water-repellentarticle has been obtained by applying the coating solution onto thesurface of the glass plate or the other substrate and then sintering ata temperature of 100-250° C. which is lower than the decompositiontemperature of the fluoroalkyl groups (250-300° C.), or simply drying atordinary temperature. The films obtained by these techniques are knownas sol-gel water-repellent films and are obtained through a processwhereby a hydrolyzable silane compound and a silane compound with awater-repellent group are hydrolyzed in a solution, subjected todehydration/condensation reaction and then coated and dried on asubstrate; in the sol-gel film, however, the solvent progressivelyevaporates as oxide bonds are formed, and therefore fine pores arepresent in the film when it is dried at 400° C. or below, so that thefilm does not have high hardness. In order to avoid the pores forincreased film hardness, it has been essential to accomplish sinteringat 500-600° C. However, heating at such high temperatures results indecomposition of the fluoroalkyl groups, making it impossible to achievethe desired water repellency. Consequently, water-repellent filmsobtained by the aforementioned technique of sintering at 250° C. orbelow, while being composed mainly of oxides, have not had the highhardness as oxides and ceramics which is achieved by, for example, meltmethods.

[0007] When such water-repellent film-coated articles are used outdoors,for example, their exposure to such conditions as blown sand readilyresults in damage to the film surface, thus impairing thewater-repellent property. The water-repellent film can also be damagedor peeled when the surface is wiped with a cloth or the like to removeattached dust, dirt or sand. Even in the absence of attached dust, etc.,abrasion with a cloth or brush made of hard fibers (such as surfacewiping of automobile window glass with a wiper, for example) forms smallnicks and further promote deterioration of the water-repellent film.

[0008] It is an object of the present invention, which has beenaccomplished in light of these problems, to provide articles coated withhigh-performance water-repellent films having high hardness that canwithstand outdoor use, a process for preparation of such water-repellentfilm-coated articles at a high rate of productivity, and a coatingliquid composition for preparation of such water-repellent film-coatedarticles.

DISCLOSURE OF THE INVENTION

[0009] As a result of much diligent research by the present inventorsaimed at overcoming the aforementioned problems, it has been discoveredthat by providing a primary oxide film with two or more componentsincluding SiO₂ and at least one type selected from among MgO, CaO, SrOand B₂O₃ in a water-repellent film-coated article having a primary oxidelayer and a water-repellent layer integrally formed by a single coatingtreatment, the hardness of the water-repellent film with the integrallyformed primary layer and water-repellent layer is drastically improved.

[0010] In other words, the present invention relates to awater-repellent film-coated article comprising a substrate and awater-repellent film composed mainly of silicon oxide and having awater-repellent group coated on the surface of the substrate, thewater-repellent film-coated article being characterized in that thewater-repellent film contains at least one type of metal oxide selectedfrom the group consisting of magnesium oxide, calcium oxide, strontiumoxide and boron oxide.

[0011] For formation of oxide films by a sol-gel method it is common touse a silicon alkoxide as the starting material, and this is because thereactivity of silicon alkoxides readily gives a uniform, transparentfilm by a milder reaction than with alkoxides of elements other thansilicon. However since, as mentioned above, the solvent progressivelyevaporates as bonds (siloxane bonds) are formed between the Si (silicon)and O (oxygen) by dehydration/condensation reaction in the sol-gelmethod, a porous silica film is obtained wherein fine pores are presentin the film. Since the Si and O bonds are covalent bonds and Si and Obond with a high bonding energy, when siloxane bonds form a somewhatthree-dimensional structure at the solvent volatilization stage,contraction of the structure is suppressed even with subsequent furtherdehydration/condensation reaction, such that a volatilized portion ofthe solvent and the alcohol produced by the dehydration/condensationreaction remains as fine pores, with silanol or unreacted alkoxyl groupspresent in the fine pores. The hardness of the porous silica film is notvery high because of its porosity. When the film is heated at atemperature of 500° C. or above, the fine pores in the film disappearproducing a non-porous silica film with high hardness, but it isdifficult to form an integral film with high hardness containingsubstances that decompose at the heating temperature.

[0012] According to the invention, the strong ionic nature of magnesium(Mg), calcium (Ca) and strontium (Sr) is utilized: they are dissolved inthe coating solution to be copresent with the thoroughly hydrolyzablesilane compound, such as a silicon alkoxide, and exist in an ionic statein the solution even at the solvent volatilization stage. Because Mg, Caand Sr are divalent, they react with silanol, eventually bonding withtwo oxygen atoms in the film interior as shown in Equation (1), andforming an “O⁻ ⁺M⁺ ⁻O” bond which has a freer bonding orientation thanan “Si—O—Si” bond, to thereby fill in the gaps of the siloxane skeleton.

[0013] When simply dried at normal temperature, for example, this filmhas about the same hardness as if a silica component alone was used, butheating at a temperature of 50-300° C. contracts the siloxane bonds byaction of the Mg (or Ca or Sr), and this eliminates pores and results ina film with high hardness and high durability comparable to inorganicglass prepared by a melt method. That is, while heating at a temperatureof 500° C. or above is necessary to eliminate the pores of a simpleporous silica film, the porous silica-based film of the invention whichcontains MgO, CaO or SrO can be rendered pore-free at a temperature of200° C. or more below that temperature. Furthermore, since the film isheated at a temperature lower than the decomposition temperature of thewater-repellent groups such as fluoroalkyl groups or alkyl groups (300°C. or higher), the fluoroalkyl groups or alkyl groups contained in thecoating solution reside on the film surface without decomposition, thusproviding excellent water repellency and durability. When only a silicacomponent with water-repellent groups is present, the film hasinsufficient hardness and low durability with heat hardening at 300° C.or below, and heating at a temperature of 500° C. or above is necessaryto eliminate the film pores and increase the film hardness, which inturn sacrifices the high water repellency.

[0014] Addition of an oxide of boron (B) to the silica also provides alow temperature hardening property and gives a pore-free film with highhardness by heating at a temperature of 300° C. or below, as withaddition of Mg, Ca or Sr described above. While it is not yet fullyunderstood why B exhibits a similar effect as Mg, Ca and Sr, it isthought to be attributable to a change in the configuration of oxygendue to the heating immediately after coating.

[0015] If the content of magnesium oxide, calcium oxide, strontium oxideand boron oxide in the water-repellent film is too low the lowtemperature hardening effect will not be obtained, while if it is toohigh the oxides will segregate to a non-uniform condition, thus loweringthe film hardness; the water-repellent film therefore preferablycontains silicon oxide, magnesium oxide, calcium oxide, strontium oxideand boron oxide in the following proportions, based on SiO₂, MgO, CaO,SrO and BO_(3/2), respectively:

[0016] silicon oxide at 70-99%, and

[0017] at least one type of metal oxide selected from the groupconsisting of magnesium oxide, calcium oxide, strontium oxide and boronoxide at a total of 1-30%,

[0018] in terms of mole percent; the water-repellent film alsopreferably contains silicon oxide, magnesium oxide, calcium oxide, boronoxide and zirconium oxide in the following proportions, based on SiO₂,MgO, CaO, BO_(3/2) and ZrO₂, respectively:

[0019] silicon oxide at 70-98%,

[0020] magnesium oxide and/or calcium oxide at 1-29%,

[0021] and boron oxide and/or zirconium oxide at 1-29%, in terms of molepercent.

[0022] Certain combinations among these give superior low temperaturehardening properties. Specifically, they are the four combinationsSi—Mg—B, Si—Ca—B, Si—Mg—Zr and Si—Ca—Zr. These sol-gel oxide filmsharden by, for example, heating at 200-250° C. for films with a filmthickness of about 150 nm and heating at about 100° C. for films with afilm thickness of a few dozen nm or less, giving water-repellent filmswith high hardness.

[0023] Thus, according to the present invention an oxide film of two ormore components including silicon oxide and at least one type selectedfrom among magnesium oxide, calcium oxide, strontium oxide and boronoxide as essential components is used as the primary oxide layer toallow elimination of pores from the primary oxide film at below thedecomposition temperature of the water-repellent layer. Water-repellentfilm-coated articles obtained thereby have high hardness or durabilitythat has not been possible in the past with water-repellent film-coatedarticles with integrally formed primary oxide layers and water-repellentlayers by a single coating treatment.

[0024] The low temperature hardening property of the water-repellentfilm of the invention is not impaired even when a transition metalelement or the like is further introduced into the silica film for thepurpose of adding another function in addition to the water-repellentfunction, such as control of the refractive index of the film or controlof the visible light transmittance. In other words, by including a metalelement exhibiting a desired function along with the Mg, Ca, Sr or B itis possible to obtain a multifunctional film having very high hardnesseven with heating at a temperature of 300° C. or below, while alsohaving both water-repellent and other functions. For example, additionof cobalt oxide, iron oxide, nickel oxide or copper oxide will impartcoloring to the water-repellent film.

[0025] When the water-repellent film of the invention contains zirconiumoxide, it may include as other components cobalt oxide, iron oxide,nickel oxide, copper oxide, aluminum oxide, gallium oxide, indium oxide,scandium oxide, yttrium oxide, lanthanum oxide, cerium oxide and zincoxide at a total of 0.5-5% in terms of mole percent, based on CoO,FeO_(3/2), NiO₂, CuO, AlO_(3/2), GaO_(3/2), InO_(3/2), ScO_(3/2),YO_(3/2), LaO_(3/2), CeO_(3/2) and ZnO.

[0026] When the water-repellent film of the invention contains nozirconium oxide, it may include as other components cobalt oxide, ironoxide, nickel oxide, copper oxide, zirconium oxide, aluminum oxide,gallium oxide, indium oxide, scandium oxide, yttrium oxide, lanthanumoxide, cerium oxide and zinc oxide at a total of 0.5-5% in terms of molepercent, based on CoO, FeO_(3/2), NiO₂, CuO, ZrO₂, AlO_(3/2), GaO_(3/2),InO_(3/2), ScO_(3/2), YO_(3/2), LaO_(3/2), CeO_(3/2) and ZnO.

[0027] In either case, addition of these components at a total in excessof 5 mole percent may produce an undesirable appearance, such as filmpeeling or film whitening.

[0028] If the thickness of the water-repellent film is too great thefilm hardness will tend to be lower, and if it is too small the filmdurability will tend to be lower. The thickness of the water-repellentfilm is therefore preferably 5-200 nm, more preferably 5-100 nm and evenmore preferably 5-50 nm. The water-repellent film preferably containsthe water-repellent groups, for example alkyl groups or fluoroalkylgroups, at 0.01-20 wt %. The water-repellent groups are present at ahigh density on the outer surface of the water-repellent film.

[0029] The present invention also provides a water-repellentfilm-coating composition containing

[0030] (A) a thoroughly hydrolyzable silane compound,

[0031] (B) a silane compound with a water-repellent group,

[0032] (C) an acid and

[0033] (D) at least one metal compound selected from the groupconsisting of magnesium, calcium, strontium and boron.

[0034] The thoroughly hydrolyzable silane compound (A) according to theinvention is not particularly limited, and tetraalkoxysilanes such astetramethoxysilane, tetraethoxysilane, tetrapropoxysilane andtetrabutoxysilane, as well as tetrachlorosilane, tetraacyloxysilane andtetraisocyanatesilane may be mentioned. Tetraalkoxysilanes are preferredfor use among these because of their relative ease of handling. Amongtetraalkoxysilanes, those of relatively low molecular weight, forexample tetraalkoxysilanes comprising alkoxyl groups of 3 or fewercarbon atoms, are preferred for use because they readily give densefilms. Also, polymers of these tetraalkoxysilanes, with averagepolymerization degrees of 5 or lower, are preferred for use.

[0035] The silane compound with a water-repellent group (B) according tothe invention is a silane compound with one, two or more water-repellentgroups (alkyl groups, fluoroalkyl groups, etc.) in the molecule, andthere may be mentioned silane compounds which are the aforementionedsilane compounds (A) a portion of which is substituted with an alkylgroup and/or fluoroalkyl group.

[0036] Examples of alkyl group-containing silane compounds include alkylgroup-containing chlorosilanes such as

[0037] CH₃(CH₂)₃₀SiCl₃, CH₃(CH₂)₂₀SiCl₃,

[0038] CH₃(CH₂)₁₈SiCl₃, CH₃(CH₂)₁₆SiCl₃,

[0039] CH₃(CH₂)₁₄SiCl₃, CH₃(CH₂)₁₂SiCl₃,

[0040] CH₃(CH₂)₁₀SiCl₃, CH₃(CH₂)₉SiCl₃,

[0041] CH₃ (CH₂)₈SiCl₃, CH₃(CH₂)₇SiCl₃,

[0042] CH₃ (CH₂)₆SiCl₃, CH₃ (CH₂)₅SiCl₃,

[0043] CH₃ (CH₂)₄SiCl₃, CH₃ (CH₂)₃SiCl₃,

[0044] CH₃(CH₂)₂SiCl₃, CH₃CH₂SiCl₃,

[0045] (CH₃CH₂)₂SiCl₂, (CH₃CH₂)₃SiCl₃,

[0046] CH₃SiCl₃, (CH₃)₂SiCl₂ (CH₃)₃SiCl;

[0047] alkyl group-containing alkoxysilanes such as

[0048] CH₃(CH₂)₃₀Si(OCH₃)₃, CH₃(CH₂)₂₀Si(OCH₃)₃,

[0049] CH₃(CH₂)₁₈Si(OCH₃)₃, CH₃(CH₂)₁₆Si(OCH₃)₃, CH₃(CH₂)₁₄Si(OCH₃)₃,CH₃(CH₂)₁₂Si(OCH₃)₃,

[0050] CH₃(CH₂)₁₀Si(OCH₃)₃, CH₃(CH₂)₉Si(OCH₃)₃,

[0051] CH₃(CH₂)₈Si(OCH₃)₃, CH₃(CH₂)₇Si(OCH₃)₃,

[0052] CH₃(CH₂)_(n)Si(OCH₃)₃, CH₃(CH₂)₅Si(OCH₃)₃,

[0053] CH₃(CH₂)₄Si(OCH₃)₃, CH₃(CH₂)₃Si(OCH₃)₃,

[0054] CH₃(CH₂)₂Si(OCH₃)₃, CH₃CH₂Si(OCH₃)₃,

[0055] (CH₃CH₂)₂Si(OCH₃)₂, (CH₃CH₂)₃SiOCH₃,

[0056] CH₃Si(OCH₃)₃₁ (CH₃)₂Si(OCH₃)₂, (CH₃)₃SiOCH₃,

[0057] CH₃(CH₂)₃₀Si(OC₂H₅)₃, CH₃(CH₂)₂₀Si(OC₂H₅)₃,

[0058] CH₃(CH₂)₁₈Si(OC₂H₅)₃, CH₃(CH₂)₁₆Si(OC₂H₅)₃,

[0059] CH₃(CH₂)₁₄Si(OC₂H₅)₃, CH₃(CH₂)₁₂Si(OC₂H₅)₃,

[0060] CH₃(CH₂)₁₀Si(OC₂H₅)₃, CH₃(CH₂)₉Si(OC₂H₅)₃,

[0061] CH₃(CH₂)₈(OC₂HS)₃, CH₃(CH₂)₇Si(OC₂H₅)₃,

[0062] CH₃(CH₂)₆Si(OC₂H₅)₃, CH₃(CH₂)₅Si(OC₂H₅)₃,

[0063] CH₃(CH₂)₄Si(OC₂H₅)₃, CH₃(CH₂)₃Si(OC₂H₅)₃,

[0064] CH₃(CH₂)₂Si(OC₂H₅)₃, CH₃CH₂Si(OC₂H₅)₃,

[0065] (CH₃CH₂)₂Si(OC₂H₅)₂, (CH₃CH₂)₃SiOC₂H₅,

[0066] CH₃Si(OC₂H₅)₃, (CH₃)₂Si(OC₂H₅)₂, (CH₃)₃SiOC₂H₅;

[0067] alkyl group-containing acyloxysilanes such as

[0068] CH₃(CH₂)₃₀Si(OCOCH₃)₃, CH₃(CH₂)₂₀Si(OCOCH₃)₃,

[0069] CH₃(CH₂)₃, Si(OCOCH₃)₃, CH₃(CH₂)₁₆Si(OCOCH₃)₃,

[0070] CH₃(CH₂)₁₄Si(OCOCH₃)₃, CH₃(CH₂)₁₂Si(OCOCH₃)₃,

[0071] CH₃(CH₂)₁₀Si(OCOCH₃)₃, CH₃(CH₂)₉Si(OCOCH₃)₃,

[0072] CH₃(CH₂)₈Si(OCOCH₃)₃, CH₃(CH₂)₇Si(OCOCH₃)₃,

[0073] CH₃(CH₂)₆Si(OCOCH₃)₃, CH₃(CH₂)₅Si(OCOCH₃)₃,

[0074] CH₃(CH₂)₄Si(OCOCH₃)₃, CH₃(CH₂)₃Si(OCOCH₃)₃,

[0075] CH₃(CH₂)₂Si(OCOCH₃)₃, CH₃CH₂Si(OCOCH₃)₃,

[0076] (CH₃CH₂)₂Si(OCOCH₃)₂, (CH₃CH₂)₃SiOCOCH₃,

[0077] CH₃Si(OCOCH₃)₃, (CH₃)₂Si(OCOCH₃)₂,

[0078] (CH₃)₃SiOCOCH₃;

[0079] and alkyl group-containing isocyanatesilanes such as

[0080] CH₃(CH₂)₃₀Si(NCO)₃, CH₃(CH₂)₂₀Si(NCO)₃,

[0081] CH₃(CH₂)₁₈Si(NCO)₃, CH₃(CH₂)₁₆Si(NCO)₃,

[0082] CH₃(CH₂)₁₄Si(NCO)₃, CH₃(CH₂)₁₂Si(NCO)₃,

[0083] CH₃(CH₂)₁₀Si(NCO)₃, CH₃(CH₂)₉Si(NCO)₃,

[0084] CH₃(CH₂)_(n)Si(NCO)₃, CH₃(CH₂)₇Si(NCO)₃,

[0085] CH₃(CH₂)₆Si(NCO)₃, CH₃(CH₂)₅Si(NCO)₃,

[0086] CH₃(CH₂)₄Si(NCO)₃, CH₃(CH₂)₃Si(NCO)₃,

[0087] CH₃(CH₂)₂Si(NCO)₃, CH₃CH₂Si(NCO)₃,

[0088] (CH₃CH₂)₂Si(NCO)₂, (CH₃CH₂)₃SiNCO,

[0089] CH₃Si(NCO)₃, (CH₃)₂Si(NCO)₂,

[0090] (CH₃)₃SiNCO.

[0091] Among these alkyl group-containing silane compounds it ispreferred to use chlorosilanes, alkoxysilanes, acyloxysilanes andisocyanatesilanes containing alkyl groups of 8 or more carbon atoms,such as the following. Octyltrimethyoxysilane CH₃(CH₂)₇Si(OCH₃)₃,octyltrichlorosilane CH₃(CH₂)₇Si(Cl)₃, nonyltrimethoxysilaneCH₃(CH₂)₈Si(OCH₃)₃, nonyltrichlorosilane CH₃(CH₂)₈Si(Cl)₃,decyltrimethoxysilane CH₃(CH₂)₉Si(OCH₃)₃, decyltrichlorosilaneCH₃(CH₂)₉Si(Cl)₃, undecyltrimethoxysilane CH₃(CH₂)₁₀Si(OCH₃)₃,undecyltrichlorosilane CH₃(CH₂)₁₀Si(Cl)₃, dodecyltrimethoxysilaneCH₃(CH₂)₁₁Si(OCH₃)₃, dodecyltrichlorosilane CH₃(CH₂)₁₁Si(Cl)₃.

[0092] Examples of fluoroalkyl group-containing silane compounds includefluoroalkyl group-containing trichlorosilanes such as

[0093] CF₃(CF₂)₁₁(CH₂)₂SiCl₃,

[0094] CF₃(CF₂)₁₀(CH₂)₂Si(Cl)₃,

[0095] CF₃(CF₂)₉(CH₂)₂SiCl₃,

[0096] CF₃(CF₂)₈(CH₂)₂SiCl₃,

[0097] CF₃(CF₂)₇(CH₂)₂SiCl₃,

[0098] CF₃(CF₂)₆(CH₂)₂SiCl₃,

[0099] CF₃(CF₂)₅(CH₂)₂SiCl₃,

[0100] CF₃(CF₂)₄(CH₂)₂SiCl₃,

[0101] CF₃(CF₂)₃(CH₂)₂SiCl₃,

[0102] CF₃(CF₂)₂(CH₂)₂SiCl₃,

[0103] CF₃CF₂ (CH₂)₂SiCl₃,

[0104] CF₃(CH₂)₂SiCl₃;

[0105] fluoroalkyl group-containing trialkoxysilanes such as

[0106] CF₃(CF₂)₁₁(C₁H₂)₂Si(OCH₃)₃,

[0107] CF₃(CF₂)₁₀(CH₂)₂Si(OCH₃)₃,

[0108] CF₃(CF₂)₉(CH₂)₂Si(OCH₃)₃,

[0109] CF₃(CF₂)₈(CH₂)₂Si(OCH₃)₃,

[0110] CF₃(CF₂)₇(CH₂)₂Si(OCH₃)₃,

[0111] CF₃(CF₂)₆(CH₂)₂Si(OCH₃)₃,

[0112] CF₃(CF₂)₅(CH₂)₂Si(OCH₃)₃,

[0113] CF₃(CF₂)₄(CH₂)₂Si(OCH₃)₃,

[0114] CF₃(CF₂)₃(CH₂)₂Si(OCH₃)₃,

[0115] CF₃(CF₂)₂(CH₂)₂Si(OCH₃)₃,

[0116] CF₃CF₂(CH₂)₂Si(OCH₃)₃,

[0117] CF₃(CH₂)₂Si(OCH₃)₃,

[0118] CF₃(CF₂)₁₁(CH₂)₂Si(OC₂H₅)₃,

[0119] CF₃(CF₂)₁₀(CH₂)₂Si(OC₂H₅)₃,

[0120] CF₃(CF₂)₉(CH₂)₂Si(OC₂H₅)₃,

[0121] CF₃(CF₂)₈ (CH₂)₂Si (OC₂H₅)₃,

[0122] CF₃(CF₂)₇(CH₂)₂Si(OC₂H₅)₃,

[0123] CF₃(CF₂)₆(CH₂)₂Si(OC₂H₅)₃,

[0124] CF₃(CF₂)₅(CH₂)₂Si(OC₂H₅)₃,

[0125] CF₃(CF₂)₄(CH₂)₂Si(OC₂H₅)₃,

[0126] CF₃(CF₂)₃(CH₂)₂Si(OC₂H₅)₃,

[0127] CF₃(CF₂)₂(CH₂)₂Si(OC₂H₅)₃,

[0128] CF₃CF₂ (CH₂)₂Si (OC₂H₅)₃,

[0129] CF₃(CH₂)₂Si(OC₂H₅)₃;

[0130] fluoroalkyl group-containing triacyloxysilanes such as

[0131] CF₃ (CF₂)₁₁(CH₂)₂Si(OCOCH₃)₃,

[0132] CF₃(CF₂)₁₀(CH₂)₂Si(OCOCH₃)₃,

[0133] CF₃(CF₂)₉(CH₂)₂Si(OCOCH₃)₃,

[0134] CF₃(CF₂)₈(CH₂)₂Si(OCOCH₃)₃,

[0135] CF₃(CF₂)₇(CH₂)₂Si(OCOCH₃)₃,

[0136] CF₃(CF₂)₆(CH₂)₂Si(OCOCH₃)₃,

[0137] CF₃(CF₂)₅(CH₂)₂Si(OCOCH₃)₃,

[0138] CF₃(CF₂)₄(CH₂)₂Si(OCOCH₃)₃,

[0139] CF₃(CF₂)₃(CH₂)₂Si(OCOCH₃)₃,

[0140] CF₃(CF₂)₂(CH₂)₂Si(OCOCH₃)₃,

[0141] CF₃CF₂ (CH₂)₂Si (OCOCH₃)₃,

[0142] CF₃ (CH₂)₂Si(OCOCH₃)₃;

[0143] and fluoroalkyl group-containing triisocyanatesilanes such as

[0144] CF₃(CF₂)₁₁(CH₂)₂Si(NCO)₃,

[0145] CF₃(CF₂)₁₀(CH₂)₂Si(NCO)₃,

[0146] CF₃(CF₂)₉(CH₂)₂Si(NCO)₃,

[0147] CF₃(CF₂)₈(CH₂)₂Si(NCO)₃,

[0148] CF₃(CF₂)₇(CH₂)₂Si(NCO)₃,

[0149] CF₃(CF₂)₆(CH₂)₂Si(NCO)₃,

[0150] CF₃(CF₂)₅(CH₂)₂Si(NCO)₃,

[0151] CF₃(CF₂)₄(CH₂)₂Si(NCO)₃,

[0152] CF₃(CF₂)₃(CH₂)₂Si(NCO)₃,

[0153] CF₃(CF₂)₂(CH₂)₂Si(NCO)₃,

[0154] CF₃CF₂(CH₂)₂Si(NCO)₃,

[0155] CF₃(CH₂)₂Si(NCO)₃.

[0156] Among these fluoroalkyl group-containing silane compounds thereare preferred trichlorosilanes, trialkoxysilanes andtriisocyanatesilanes containing fluoroalkyl groups with 10 or morefluorine atoms, of which CF₃(CF₂)₇(CH₂)₂Si(OCH₃)₃ (heptadecafluorodecyltrimethoxysilane) and CF₃(CF₂)₇ (CH₂)₂SiCl₃ (heptadecafluorodecyltrichlorosilane) are particularly preferred.

[0157] The acid (C) according to the invention is preferably a volatileacid such as hydrochloric acid, hydrofluoric acid, nitric acid, aceticacid, formic acid, trifluoroacetic acid or the like from the standpointof volatilization by drying at ordinary temperature without remaining inthe film, and hydrochloric acid is particularly preferred among thesebecause of its high degree of electrolytic dissociation andvolatilization and its relative safety during handling.

[0158] At least one type of metal compounds selected from the groupconsisting of magnesium, calcium, strontium and boron (D) according tothe invention may be any chlorides, oxychlorides, oxides, hydroxides,nitrates, oxynitrates, etc. of the aforementioned metals, so long asthey undergo simple electrolytic dissociation to dissolve in water oralcohol. Among these, it is particularly preferred to use chlorides,oxychlorides, nitrates and oxynitrates.

[0159] Specific examples for component (D) include MgCl₂, Mg(NO₃)₂,CaCl₂, Ca(NO₃)₂, SrCl₂, Sr(NO₃)₂ and H₃BO₃.

[0160] The zirconium oxide is not an essential component, but includingit with the magnesium oxide or calcium oxide increases the lowtemperature hardening property, and therefore a zirconium compound, forexample a chloride, oxychloride, oxide, hydroxide, nitrate oroxynitrate, which undergoes simple electrolytic dissociation to dissolvein water or alcohol, may be included in the water-repellent film-coatingcomposition. Specific examples of such compounds include ZrOCl₂ andZrO(NO₃)₂.

[0161] As an additional component (component (E)) there may be added tothe water-repellent film-coating composition at least one metal compoundselected from the group consisting of cobalt, iron, nickel, copper,aluminum, gallium, indium, scandium, yttrium, lanthanum, cerium andzinc, such as a chloride, oxychloride, oxide, hydroxide, nitrate oroxynitrate of one or more of these metals, as the starting material forcobalt oxide, iron oxide, nickel oxide, copper oxide, aluminum oxide,gallium oxide, indium oxide, scandium oxide, yttrium oxide, lanthanumoxide, cerium oxide and zinc oxide, for the purpose of imparting theaforementioned functions of control of the refractive index of the filmor control of the visible light transmittance. Any of these compoundsare suitable so long as they dissociate in water or alcohol, and thosethat undergo simple electrolytic dissociation are especially preferred.In other words, it preferably decomposes without producing oxideprecipitation, etc., and is present in the coating solution in an ionstate.

[0162] Specific examples of the aforementioned component (E) includeAlCl₃, GaCl₃, InCl₃, SCCl₃, YCl₃, LaCl₃, CeCl₃, CoCl₂, ZnCl₂, Al(NO₃)₃,Ga(NO₃)₃, In(NO₃)₃, Sc(NO₃)₃, Y(NO₃)₃, La(NO₃)₃, Ce(NO₃)₃, Co(NO₃)₂,Zn(NO₃)₂.

[0163] The water-repellent film-coating composition preferably containsthe silane compound (A) at 0.01-2 wt % based on silica, the silanecompound (B) at 0.00001-0.15 wt % based on silica, the acid at 0.001-3N, water at 0-5 wt %, the compound (D) at a molar ratio of 0.01-0.4 withrespect to the silane compound (A), and the component (E) at a molarratio of 0-0.4 with respect to the silane compound (A).

[0164] The solvent for the water-repellent film-coating composition isnot particularly limited, but hydrocarbons such as hexane, toluene andcyclohexane, halogenated hydrocarbons such as methyl chloride, carbontetrachloride and trichloroethylene, ketones such as acetone and methylethyl ketone, nitrogen-containing compounds such as diethylamine, esterssuch as ethyl acetate, and alcohols may be used. Preferred for use amongthese are alcohol-based solvents, examples of which include methanol,ethanol, 1-propanol, 2-propanol, butyl alcohol, amyl alcohol and thelike among which straight-chain saturated monohydric alcohols of 3 orfewer carbon atoms, such as methanol, ethanol, 1-propanol and 2-propanolare even more preferred for use because of their high volatilizationrates at ordinary temperature.

[0165] These alcohols may also contain water at from 0 wt % to 50 wt %.Commercially available high-grade alcohols usually contain water at 0.2wt % or more, and according to the invention they are preferably used toavoid cost-raising treatments such as dewatering treatment. For additionof the metal starting materials, even when the metal compounds are addedafter first being dissolved in water, the amount of water in the finalwater-repellent film-coating composition may be 50 wt % or less withrespect to the amount of solvent. The amount of water is preferably notgreater than 50 wt % because this will prevent a uniform, transparentfilm from being formed.

[0166] A preferred water-repellent film-coating composition according tothe invention contains

[0167] (A) a thoroughly hydrolyzable silane compound or its hydrolysateat 0.01-2 wt % (based on silica),

[0168] (B) a silane compound with a water-repellent group at0.00001-0.15 wt % (based on silica),

[0169] (C) an acid at 0.001-3 N,

[0170] (D) at least one type of metal compound selected from the groupconsisting of magnesium, calcium, strontium and boron at a molar ratioof 0.01-0.4 based on MgO, CaO, SrO and BO_(3/2), with respect to thesilane compound (A),

[0171] (E) at least one type of metal compound selected from the groupconsisting of cobalt, iron, nickel, copper, zirconium, aluminum,gallium, indium, scandium, yttrium, lanthanum, cerium and zinc at amolar ratio of 0-0.4 based on CoO, FeO_(3/2), NiO₂, CuO, AlO_(3/2),GaO_(3/2), InO_(3/2), ScO_(3/2), YO_(3/2), LaO_(3/2), CeO_(3/2) and ZnO,with respect to the silane compound (A),

[0172] (F) water at 0-20 wt % and

[0173] (G) an alcohol constituting the remainder.

[0174] An even more preferred water-repellent film-coating compositioncontains

[0175] (A) a thoroughly hydrolyzable silane compound or its hydrolysateat 0.01-2 wt % (based on silica),

[0176] (B) a silane compound with a water-repellent group at0.00001-0.15 wt % (based on silica),

[0177] (C) an acid at 0.001-3 N,

[0178] (D-1) a magnesium and/or calcium compound at a molar ratio of0.01-0.4 based on MgO and CaO, with respect to the silane compound (A)(based on SiO₂),

[0179] (D-2) a boron and/or zirconium compound at a molar ratio of0.01-0.4 based on BO_(3/2) and ZrO₂, with respect to the silane compound(A) (based on SiO₂),

[0180] (E) at least one type of metal compound selected from the groupconsisting of cobalt, iron, nickel, copper, aluminum, gallium, indium,scandium, yttrium, lanthanum, cerium and zinc at a molar ratio of 0-0.4based on CoO, FeO_(3/2), NiO₂, CuO, AlO_(3/2), GaO_(3/2), InO_(3/2),ScO_(3/2), YO_(3/2), LaO_(3/2), CeO_(3/2) and ZnO, with respect to thesilane compound (A) (based on SiO₂),

[0181] (F) water at 0-20 wt % and

[0182] (G) an alcohol constituting the remainder.

[0183] The method of coating the water-repellent film-coatingcomposition of the invention is not particularly limited, but preferablythe substrate is evenly wetted with the coating solution composition andthen stationed for drying to hardness. This allows formation of a highlyoriented water-repellent layer as the fluoroalkyl groups and alkylgroups collect on the liquid surface during volatilization of thesolvent. Here, the stationing is sufficient so long as the coatingsolution applied to the substrate is not disturbed, and the substratemay even be gently moved in a parallel direction during the application.

[0184] Specific examples of coating methods include dip coating, flowcoating, curtain coating, spin coating, spray coating, bar coating, rollcoating, brush coating and the like.

[0185] The drying according to the invention is carried out in anatmosphere at room temperature or a temperature of 300° C. or below, andpreferably at 40% or lower relative humidity. The coated state of thehighly oriented surface is therefore maintained without decomposition ofthe integrally coated alkyl groups or fluoroalkyl groups. As a result itis possible to obtain a water-repellent film with a low temperaturehardening property as well as excellent water-repellent performanceincluding droplet roll-over properties and excellent durability due toits high hardness. Because of the low heating temperature, even when analkali component is present in the substrate there is low diffusionthereof in the water-repellent film, thus preventing reduction indurability of the water-repellent property due the alkali.

[0186] As substrates for the invention there may be mentionedtransparent and non-transparent plates, bars and other various forms ofglass, ceramic, plastic or metal. When few hydrophilic groups arepresent on the surface of the substrate, it is preferred to pretreat thesurface with an oxygen-containing plasma or corona atmosphere forhydrophilic treatment, or to irradiate the substrate surface withultraviolet rays of a wavelength near 200-300 nm in an oxygen-containingatmosphere for hydrophilic treatment, followed by surface treatment.

BEST MODE FOR CARRYING OUT THE INVENTION

[0187] Embodiments of the present invention will now be explained indetail by way of examples.

EXAMPLE 1

[0188] To 97.68 g of ethanol (moisture content: 0.35 wt %) there wereadded 0.02 g of heptadecafluorodecyl trimethoxysilane(CF₃(CF₂)₇(CH₂)₂Si(OCH₃)₃, product of Shinetsu Silicone), 0.24 g oftetraethoxysilane (Si(OCH₂CH₃)₄, product of Shinetsu Silicone), 0.0586 gof magnesium chloride hexahydrate (product of Kanto Kagaku) and 2 g ofconcentrated hydrochloric acid (35 wt %, product of Kanto Kagaku) whilestirring, to obtain a coating solution. Table 1 shows the types andamounts (molar ratios) of the tetraethoxysilane (TEOS),heptadecafluorodecyl trimethoxysilane (FAS), and magnesium or calciumstarting materials in the coating solution. The total weight of the TEOSand magnesium starting material (or calcium starting material) in thecoating solution (wt % based on SiO₂, MgO and CaO) was 0.08 wt %. Thiswater-repellent coating solution was applied to the surface of a washedsoda lime silicate glass-composed glass substrate (3.4 mm×150×150 mm) at30% humidity and room temperature (20° C.) using a flow coating method,and then dried at room temperature for about one minute to obtain awater-repellent glass plate. The composition of the water-repellent filmwas as shown in Table 1. The value for the water-repellent groups isgiven with respect to 100 mole percent as the total for all of theoxides, and it was 2.4 mole percent based on FAS (likewise for thefollowing examples and comparative examples). The proportion ofwater-repellent groups (the CF₃(CF₂)₇(CH₂)₂— portion) was 16 wt % withrespect to the total weight of the film.

[0189] The water contact angle for the resulting water-repellent glassplate was measured using a contact angle instrument (CA-DT, product ofKyowa Surfactant Chemistry, KK.), as the static contact angle for awater droplet of 2 mg weight. A larger value for the contact angleindicates better static water repellency.

[0190] As an index for the roll-over performance of water droplets onthe surface of the water-repellent glass plate, a 5-mm diameter waterdroplet was placed on the horizontally positioned water-repellent glassplate surface, and then the water-repellent glass plate was slowlytilted until the water droplet placed on the surface first began toroll, at which point the tilt angle (critical tilt angle) of the glassplate was measured. A smaller critical tilt angle indicates betterdynamic water repellency, and for example, better dispersion of raindroplets adhering to the front glass window of a moving automobile, thuscausing less blockage of the field of vision of the driver.

[0191] Evaluation of the hardness of the water-repellent film wascarried out according to the abrasion test specified by JIS R 3212.Specifically, a commercially available Taber abrasion test was conductedwith 1000 abrasion passes at a weight of 500 g, with measurement of thehaze value before and after the abrasion test and optical microscopeobservation of any film peeling before and after the abrasion test. Thefilm was checked for peeling after the abrasion test, and any film thatexhibited no peeling was also measured for haze value.

[0192] Table 2 shows the film thickness, contact angle, critical tiltangle, haze value before and after the Taber abrasion test and filmpeeling before and after the abrasion test for the water-repellent film.The resulting film had an especially low critical tilt angle of 40, andthis was believed to indicate that the Mg ions had filled the gaps inthe silica porous body, thus improving the smoothness of the film.

EXAMPLES 2-10

[0193] Water-repellent glass was obtained in the same manner as Example1, except that the metal atom starting materials and addition amounts inthe coating solution of Example 1 were changed to those shown inTable 1. The compositions of the water-repellent films were as shown inTable 1. The results of measurement in the same manner as Example 1 areshown in Table 2. The total weight of the TEOS and magnesium startingmaterial (or calcium or strontium starting material) in the coatingsolutions (wt % based on SiO₂, MgO, CaO or SrO) was 0.08 wt %.

[0194] The films obtained in the same manner as Example 1 had very lowcritical tilt angles of 4°, and this was believed to indicate that theMg, Ca and Sr ions had filled the gaps in the silica porous bodies, thusimproving the smoothness of the films.

COMPARATIVE EXAMPLE 1

[0195] To 85.3 g of ethanol there were added 40 g of tetraethoxysilaneand 1.92 g of heptadecafluorodecyl trimethoxysilane, and after 20minutes of stirring, 16.6 g of water and 20.8 g of 0.1 N hydrochloricacid were added and the mixture was stirred for 2 hours, placed in asealed container and allowed to stand at 25° C. for 24 hours to obtain awater-repellent coating solution. The composition of the water-repellentcoating solution is shown in Table 1. A washed glass plate was immersedin the water-repellent coating solution and lowered for coating, andafter drying it was fired at 250° C. for one hour to obtain awater-repellent glass plate. The composition of the water-repellent filmwas as shown in Table 1. The TEOS weight in the coating solution (basedon SiO₂) was 6.5 wt %.

[0196] As shown in Table 2, the resulting water-repellent glass platehad an initial critical tilt angle of 18°, which was large compared toExamples 1-7, and poor water droplet roll-over. When Comparative Example1 was dried at room temperature instead of at 250° C. for one hour, thewater droplet roll-over was unchanged but the film underwentconsiderable scratching by mere light rubbing with a cloth.

COMPARATIVE EXAMPLE 2

[0197] To 97.68 g of ethanol (moisture content: 0.35 wt %) there wereadded 0.02 g of heptadecafluorodecyl trimethoxysilane(CF₃(CF₂)₇(CH₂)₂Si(OCH₃)₃, product of Shinetsu Silicone), 0.3 g oftetraethoxysilane (Si(OCH₂CH₃)₄, product of Shinetsu Silicone) and 2 gof concentrated hydrochloric acid (35 wt %, product of Kanto Kagaku)while stirring, to obtain a coating solution. A water-repellent glassplate was otherwise obtained in the same manner as Example 1. Thecomposition of the water-repellent film was as shown in Table 1. Theweight of the TEOS in the coating solution (based on SiO₂) was 0.08 wt%.

[0198] As shown in Table 2, the resulting water-repellent glass platehad an initial critical tilt angle of 8°, which was large compared toExamples 1-7, and inferior droplet roll-over. Even when ComparativeExample 2 was heated at 200° C. for 30 minutes instead of drying at roomtemperature, peeling of the film occurred after the abrasion test. TABLE1 Component Water- ratio Film composition repellent (molar (mole %)groups Starting material ratio) SiO₂ MgO CaO SrO (based on FAS) Examples1 TEOS/MgCl₂.6H₂O 80/20 80 20 0 0 2.4 2 TEOS/Mg(NO₃)₂.6H₂O 80/20 80 20 00 2.4 3 TEOS/Mg(OH)₂.6H₂O 80/20 80 20 0 0 2.4 4 TEOS/MgO 80/20 80 20 0 02.4 5 TEOS/CaCl₂ 80/20 80 0 20 0 2.4 6 TEOS/Ca(NO₃)₂.4H₂O 80/20 80 0 200 2.4 7 TEOS/Ca(OH)₂.4H₂O 80/20 80 0 20 0 2.4 8 TEOS/SrCl₂ 80/20 80 0 020 2.4 9 TEOS/Sr(NO₃)₂ 80/20 80 0 0 20 2.4 10 TEOS/Sr(OH)₂.8H₂O 80/20 800 0 20 2.4 Comparative Examples 1 TEOS 100 0 0 0 1.8 2 TEOS 100 0 0 02.4

[0199] TABLE 2 Haze value Critical Haze value (%) after Film Contacttilt (%) before abrasion thickness angle angle abrasion test/film (nm)(degree) (degree) test peeling Example 1 30 108 4 0.0 peeling Example 230 108 4 0.0 peeling Example 3 30 108 4 0.0 peeling Example 4 30 108 40.0 peeling Example 5 30 108 4 0.0 peeling Example 6 30 108 4 0.0peeling Example 7 30 108 4 0.0 peeling Example 8 30 108 4 0.0 peelingExample 9 30 108 4 0.0 peeling Example 10 30 108 4 0.0 peelingComparative 40 100 15 0.0 peeling Example 1 Comparative 40 108 7 0.0peeling Example 2

EXAMPLES 11-32

[0200] Water-repellent glass was obtained in the same manner as Example1, except that the metal atom starting materials and addition amounts inthe coating solution of Example 1 and the drying temperature and timeafter coating were changed to those shown in Table 3. The compositionsof the water-repellent films were as shown in Tables 4 and 5. Theresults of measurement in the same manner as Example 1 are shown inTable 6. The total content of the TEOS and different metal oxidestarting materials in the coating solutions (wt % based on SiO₂, MgO,CaO, B₂O₃, Al₂O₃, Ga₂O₃, In₂O₃, Sc₂O₃, Y₂O₃, La₂O₃, Ce₂O₃, CoO, ZnO,ZrO₂) was 0.08 wt %.

[0201] The resulting films had small initial critical tilt angles of5-8°, and were very hard water-repellent films with no film peeling evenafter Taber abrasion.

EXAMPLES 33-36

[0202] Water-repellent glass was obtained in the same manner as Example1, except that the metal atom starting materials and addition amounts inthe coating solution of Example 1 and the drying temperature and timeafter coating were changed to those shown in Table 7. The compositionsof the water-repellent films were as shown in Table 8. The results ofmeasurement in the same manner as Example 1 are shown in Table 9. Thetotal content of the TEOS and different metal oxide starting materialsin the coating solutions (wt % based on SiO₂, MgO, CaO and B₂O₃) was0.08 wt %.

[0203] The resulting films had small initial critical tilt angles of5-7°, and were very hard water-repellent films with no film peeling evenafter Taber abrasion.

EXAMPLES 37-40

[0204] Water-repellent glass was obtained in the same manner as Example1, except that heptadecafluorodecyl trimethoxysilane was changed tododecyltrimethoxysilane (CH₃(CH₂)₉Si(OCH₃)₃, product of Tokyo Kasei,hereunder also referred to as “AS”), and the metal atom startingmaterials and addition amounts in the coating solution of Example 1 andthe drying temperature and time after coating were changed to thoseshown in Table 7. The compositions of the water-repellent films were asshown in Table 8. The results of measurement in the same manner asExample 1 are shown in Table 9. The total content of the TEOS anddifferent metal oxide starting materials in the coating solutions (wt %based on SiO₂, MgO, CaO, B₂O₃ and ZrO₂) was 0.08 wt %.

[0205] The resulting films had small critical tilt angles, thoughslightly larger than Example 1, and were hard water-repellent films withno film peeling even after Taber abrasion.

EXAMPLES 41-60

[0206] Water-repellent glass was obtained in the same manner as Example1, except that the metal atom starting materials and addition amounts inthe coating solution of Example 1 and the drying temperature and timeafter coating were changed to those shown in Table 10. The compositionsof the water-repellent films were as shown in Table 11. The results ofmeasurement in the same manner as Example 1 are shown in Table 12. Thetotal content of the TEOS and different metal oxide starting materialsin the coating solutions (wt % based on SiO₂, MgO, CaO, B₂O₃, Al₂O₃,CoO, Fe₂O₃, NiO and CuO) was 0.08 wt %.

[0207] The resulting films had small critical tilt angles, thoughslightly larger than Example 1, and were hard water-repellent films withno film peeling even after Taber abrasion.

[0208] Also, coloration due to the added transition metals was found inExamples 43-50 and 53-60, so that the resulting water-repellent filmswere very hard and colored.

COMPARATIVE EXAMPLES 3 AND 4

[0209] Water-repellent glass was obtained in the same manner as Example1, except that the metal atom starting materials and addition amounts inthe coating solution of Example 1 and the drying temperature and timeafter coating were changed to those shown in Table 13. The results ofmeasurement in the same manner as Example 1 are shown in Table 14. Thetotal content of the TEOS and different metal oxide starting materialsin the coating solutions (wt % based on SiO₂, La₂O₃ and CoO) was 0.08 wt%.

[0210] Comparative Examples 3 and 4 both had inferior outer appearancesof the films, and their hardnesses were such that the films completelypeeled off after the Taber test. TABLE 3 Com- ponent ratio Heating Exam-(molar temperature/ ple Starting material ratio) time 11TEOS/MgCl₂.6H₂O/H₃BO₃ 98/1/1 100° C.-30 min. 12 TEOS/CaCl₂/H₃BO₃ 98/1/1100° C.-30 min. 13 TEOS/MgCl₂.6H₂O/AlCl₃.6H₂O 97/2/1 200° C.-30 min. 14TEOS/CaCl₂/AlCl₃.6H₂O 97/2/1 200° C.-30 min. 15 TEOS/MgCl₂6H₂O/GaCl₃97/2/1 200° C.-30 min. 16 TEOS/CaCl₂/GaCl₃ 97/2/1 200° C.-30 min. 17TEOS/MgCl₂ 6H₂O/Incl₃.4H₂O 97/2/1 200° C.-30 min. 18TEOS/CaCl₂/InCl₃.4H₂O 97/2/1 200° C.-30 min. 19TEOS/MgCl₂6H₂O/ScCl₃.6H₂O 97/2/1 200° C.-30 min. 20TEOS/CaCl₂/ScCl₃.6H₂O 97/2/1 200° C.-30 min. 21 TEOS/MgCl₂6H₂O/YCl₃.6H₂O97/2/1 200° C.-30 min. 22 TEOS/CaCl₂/YCl₃.6H₂O 97/2/1 200° C.-30 min. 23TEOS/MgCl₂6H₂O/LaCl₃.7H₂O 97/2/1 200° C.-30 min. 24TEOS/CaCl₂/LaCl₃.7H₂O 97/2/1 200° C.-30 min. 25TEOS/MgCl₂6H₂O/CeCl₃.7H₂O 97/2/1 200° C.-30 min. 26TEOS/CaCl₂/CeCl₃.7H₂O 97/2/1 200° C.-30 min. 27TEOS/MgCl₂.6H₂O/CoCl₂.6H₂O 97/2/1 200° C.-30 min. 28TEOS/CaCl₂/CoCl₂.6H₂O 97/2/1 200° C.-30 min. 29 TEOS/MgCl₂.6H₂O/ZnCl₂97/2/1 200° C.-30 min. 30 TEOS/CaCl₂/ZnCl₂ 97/2/1 200° C.-30 min. 31TEOS/MgCl₂.6H₂O/ZrOCl₂.8H₂O 98/1/1 100° C.-30 min. 32TEOS/CaCl₂/ZrOCl₂.8H₂O 98/1/1 100° C.-30 min.

[0211] TABLE 4 Water-repellent Film composition (mole %) groups ExampleSiO₂ MgO CaO B₂O₃ Al₂O₃ Ga₂O₃ In₂O₃ Sc₂O₃ (based on FAS) 11 98.5 1.0 00.5 0 0 0 0 2.4 12 98.5 0 1.0 0.5 0 0 0 0 2.4 13 97.5 2.0 0 0 0.5 0 0 02.4 14 97.5 0 2.0 0 0.5 0 0 0 2.4 15 97.5 2.0 0 0 0 0.5 0 0 2.4 16 97.50 2.0 0 0 0.5 0 0 2.4 17 97.5 2.0 0 0 0 0 0.5 0 2.4 18 97.5 0 2.0 0 0 00.5 0 2.4 19 97.5 2.0 0 0 0 0 0 0.5 2.4 20 97.5 0 0 0 0 0 0 0.5 2.4

[0212] TABLE 5 Water-repellent Film composition (mole %) groups ExampleSiO₂ MgO CaO ZrO₂ Y₂O₃ La₂O₃ Ce₂O₃ CoO ZnO (based on FAS) 21 97.5 2.0 00 0.5 0 0 0 0 2.4 22 97.5 0 2.0 0 0.5 0 0 0 0 2.4 23 97.5 2.0 0 0 0 0.50 0 0 2.4 24 97.5 0 2.0 0 0 0.5 0 0 0 2.4 25 97.0 2.0 0 0 0 0 1.0 0 02.4 26 97.0 0 2.0 0 0 0 1.0 0 0 2.4 27 97.0 2.0 0 0 0 0 0 1.0 0 2.4 2897.0 0 2.0 0 0 0 0 1.0 0 2.4 29 97.0 2.0 0 0 0 0 0 0 1.0 2.4 30 97.0 02.0 0 0 0 0 0 1.0 2.4 31 98.0 1.0 0 1.0 0 0 0 0 0 2.4 32 98.0 0 2.0 1.00 0 0 0 0 2.4

[0213] TABLE 6 Critical Haze Haze value (%) Film Contact tilt value (%)after abrasion thickness angle angle before test/film Example (nm)(degree) (degree) abrasion test peeling 11 30 109 6 0.0 1.2 12 30 110 60.1 0.9 13 30 108 7 0.2 1.1 14 30 107 8 0.1 1.3 15 30 107 7 0.1 1.1 1630 108 7 0.1 1.2 17 30 109 7 0.2 1.2 18 30 108 8 0.1 1.4 19 30 107 8 0.11.1 20 30 108 7 0.0 1.1 21 30 107 7 0.1 1.3 22 30 107 8 0.0 1.1 23 30107 8 0.0 1.2 24 30 107 8 0.1 1.4 25 30 108 8 0.0 1.2 26 30 107 7 0.21.3 27 30 107 8 0.1 1.2 28 30 108 7 0.1 1.4 29 30 108 8 0.1 1.2 30 30107 8 0.0 1.3 31 30 109 5 0.0 0.9 32 30 109 6 0.0 1.0

[0214] TABLE 7 Component Heating Exam- ratio temperature/ ple Startingmaterial (molar ratio) time 33 TEOS/MgCl₂.6H₂O 80/20 200° C.-30 min. 34TEOS/CaCl₂ 80/20 200° C.-30 min. 35 TEOS/H₃BO₃ 95/5 200° C.-30 min. 36TEOS/H₃BO₃ 99/1 200° C.-30 min. 37 TEOS/MgCl₂.6H₂O/H₃BO₃ 98/1/1 200°C.-30 min. 38 TEOS/CaCl₂/H₃BO₃ 98/1/1 200° C.-30 min. 39TEOS/MgCl₂.6H₂O/ 98/1/1 200° C.-30 min. ZrOCl₂.8H₂O 40TEOS/CaCl₂/ZrOCl₂.8H₂O 98/1/1 200 ° C.-30 min.

[0215] TABLE 8 Film composition (mole %) Water-repellent groups ExampleSiO₂ MgO CaO B₂O₃ ZrO₂ (based on FAS or AS) 33 80 20 0 0 0 0.036 34 80 020 0 0 0.036 35 95 0 0 5 0 0.036 36 99 0 0 1 0 0.036 37 98.5 1 0 0.5 00.036 38 98.5 0 1 0.5 0 0.036 39 98.0 1 0 0 1 0.036 40 98.0 0 1 0 10.036

[0216] TABLE 9 Critical Haze Haze value (%) Film Contact tilt value (%)after abrasion thickness angle angle before test/film Example (nm)(degree) (degree) abrasion test peeling 33 30 109 6 0.0 1.1 34 30 109 70.0 1.2 35 30 109 6 0.0 1.1 36 30 109 5 0.0 1.0 37 30 109 6 0.0 1.0 3830 109 6 0.0 1.0 39 30 109 5 0.0 0.9 40 30 109 6 0.0 1.0

[0217] TABLE 10 Exam- Starting material Heating temperature/ ple(component ratio (molar ratio)) time 41TEOS/MgCl₂.6H₂O/H₃BO₃/AlCl₃.6H₂O(96/2/1/1) 200° C.-30 min. 42TEOS/CaCl₂/H₃BO₃/AlCl₃.6H₂O(96/2/1/1) 200° C.-30 min. 43TEOS/MgCl₂.6H₂O/H₃BO₃/CoCl₂.6H₂O(93/2/1/4) 200° C.-30 min. 44TEOS/CaCl₂/H₃BO₃/CoCl₂.6H₂O(93/2/1/4) 200° C.-30 min. 45TEOS/MgCl₂.6H₂O/H₃BO₃/FeCl₂ (93/2/1/4) 200° C.-30 min. 46TEOS/CaCl₂/H₃BO₃/FeCl₂ (93/2/1/4) 200° C.-30 min. 47TEOS/MgCl₂.6H₂O/H₃BO₃/NiCl₂.6H₂O(93/2/1/4) 200° C.-30 min. 48TEOS/CaCl₂/H₃BO₃/NiCl₂.6H₂O(93/2/1/4) 200° C.-30 min. 49TEOS/MgCl₂.6H₂O/H₃BO₃/CuCl₂.4H₂O(93/2/1/4) 200° C.-30 min. 50TEOS/CaCl₂/H₃BO₃/CuCl₂.4H₂O(93/2/1/4) 200° C.-30 min. 51TEOS/MgCl₂.6H₂O/ZrO(NO₃)₂.8H₂O/AlCl₃.6H₂O(96/2/1/1) 200° C.-30 min. 52TEOS/CaCl₂/ZrO(NO₃)₂.8H₂O/AlCl₃.6H₂O(96/2/1/1) 200° C.-30 min. 53TEOS/MgCl₂.6H₂O/ZrOCl₂.8H₂O/CoCl₂.6H₂O(96/2/1/4) 200° C.-30 min. 54TEOS/CaCl₂/ZrOCl₂.8H₂O/CoCl₂.6H₂O(93/2/1/4) 200° C.-30 min. 55TEOS/MgCl₂.6H₂O/ZrOCl₂.8H₂O/FeCl₂ (93/2/1/4) 200° C.-30 min. 56TEOS/CaCl₂/ZrOCl₂.8H₂O/FeCl₂ (93/2/1/4) 200° C.-30 min. 57TEOS/MgCl₂.6H₂O/ZrOCl₂.8H₂O/NiCl₂.6H₂O(93/2/1/4) 200° C.-30 min. 58TEOS/CaCl₂/ZrOCl₂.8H₂O/NiCl₂.6H₂O(93/2/1/4) 200° C.-30 min. 59TEOS/MgCl₂.6H₂O/ZrOCl₂.8H₂O/CuCl₂.4H₂O(93/2/1/4) 200° C.-30 min. 60TEOS/CaCl₂/ZrOCl₂.8H₂O/CuCl₂.4H₂O(93/2/1/4) 200° C.-30 min.

[0218] TABLE 11 Film composition (mole %) Example SiO₂ MgO CaO B₂O₃ ZrO₂Al₂O₃ CoO Fe₂O₃ NiO CuO 41 97.0 2.0 0 0.5 0 0.5 0 0 0 0 42 97.0 0 2.00.5 0 0.5 0 0 0 0 43 93.5 2.0 0 0.5 0 0 4.0 0 0 0 44 93.5 0 2.0 0.5 0 04.0 0 0 0 45 95.4 2.1 0 0.5 0 0 0 2.1 0 0 46 95.4 0 2.1 0.5 0 0 0 2.1 00 47 93.5 2.0 0 0.5 0 0 0 0 4.0 0 48 93.5 0 2.0 0.5 0 0 0 0 4.0 0 4993.5 2.0 0 0.5 0 0 0 0 0 4.0 50 93.5 0 2.0 0.5 0 0 0 0 0 4.0 51 96.5 2.00 0 1.0 0.5 0 0 0 0 52 96.5 0 2.0 0 1.0 0.5 0 0 0 0 53 96.0 2.0 0 0 1.00 4.0 0 0 0 54 96.0 0 2.0 0 1.0 0 4.0 0 0 0 55 94.9 2.0 0 0 1.0 0 0 2.00 0 56 94.9 0 2.0 0 1.0 0 0 2.0 0 0 57 93.0 2.0 0 0 1.0 0 0 0 4.0 0 5893.0 0 2.0 0 1.0 0 0 0 4.0 0 59 93.0 2.0 0 0 1.0 0 0 0 0 4.0 60 93.0 02.0 0 1.0 0 0 0 0 4.0

[0219] TABLE 12 Critical Haze Haze value (%) Film Contact tilt value (%)after abrasion thickness angle angle before test/film Example (nm)(degree) (degree) abrasion test peeling 41 30 109 6 0.0 1.2 42 30 110 60.1 0.9 43 30 108 7 0.2 1.1 44 30 107 8 0.1 1.3 45 30 107 7 0.1 1.1 4630 108 7 0.1 1.2 47 30 109 7 0.2 1.2 48 30 108 8 0.1 1.4 49 30 107 8 0.11.1 50 30 108 7 0.0 1.1 51 30 107 7 0.1 1.3 52 30 107 8 0.0 1.1 53 30107 8 0.0 1.2 54 30 107 8 0.1 1.4 55 30 108 8 0.0 1.2 56 30 107 7 0.21.3 57 30 107 8 0.1 1.2 58 30 108 7 0.1 1.4 59 30 108 8 0.1 1.2 60 30107 8 0.0 1.3

[0220] TABLE 13 Comparative Starting material Heating Example (molarratio) temperature/time 3 TEOS/CoCl₂.6H₂O(98/2) 250° C.-30 min. 4TEOS/LaCl₃.7H₂O(98/2) 250° C.-30 min.

[0221] TABLE 14 Haze value (%) after Film Contact Critical Haze valueabrasion Comparative thickness angle tilt angle (%) before test/filmExample (nm) (degree) (degree) abrasion test peeling 3 30 107 8 11.1peeling 4 30 107 7 8.1 peeling

INDUSTRIAL APPLICABILITY

[0222] As explained above, by providing a primary oxide film as acomposite oxide film with two or more components including SiO₂ and atleast one selected from among MgO, CaO, SrO and B₂O₃ in awater-repellent film-coated article having an integrally formed primaryoxide layer and a water-repellent layer by a single coating treatmentaccording to the present invention, it is possible to drasticallyimprove the hardness of the water-repellent film with the integrallyformed primary layer and water-repellent layer. According to theinvention there is no need for high-temperature sintering afterformation of the water-repellent film, and therefore large-sizedequipment is not required so that preparation costs may be reduced.

[0223] Moreover, since a silane compound including water-repellentgroups such as alkyl groups or fluoroalkyl groups is added to thewater-repellent coating solution, it is possible to form the primaryoxide layer and water-repellent layer by application of one type ofsolution, thus allowing better productivity.

[0224] In addition, since the water-repellent groups are naturallyoriented during film formation according to the invention, it ispossible to form a water-repellent layer with satisfactory orientation.The water-repellent articles of the invention therefore have veryexcellent water droplet roll-over properties and high abrasionresistance.

What is claimed is:
 1. A water-repellent film-coated article comprisinga substrate and a water-repellent film, composed of silicon oxide and atleast one of metal oxide selected from the group consisting of magnesiumoxide, calcium oxide, strontium oxide and boron oxide and having awater-repellent group, coated on the surface of the substrate.
 2. Awater-repellent film-coated article according to claim 1, wherein saidwater-repellent film contains silicon oxide at 70-99 mole percent (basedon SiO₂), at least one of metal oxide selected from the group consistingof magnesium oxide, calcium oxide, strontium oxide and boron oxide at atotal of 1-30 mole percent (based on MgO, CaO, SrO and BO_(3/2)), and awater-repellent group at 0.01-20 wt %.
 3. A water-repellent film-coatedarticle according to claim 2, wherein said water-repellent film furthercontains, in terms of mole percent, at least one of metal oxide selectedfrom the group consisting of zirconium oxide, aluminum oxide, galliumoxide, indium oxide, scandium oxide, yttrium oxide, lanthanum oxide,cerium oxide, cobalt oxide, iron oxide, nickel oxide, copper oxide andzinc oxide at 0.5-5%, based on ZrO₂, AlO_(3/2), GaO_(3/2), InO_(3/2),ScO_(3/2), YO_(3/2), LaO_(3/2), CeO_(3/2), CoO, FeO_(3/2), NiO₂, CuO andZnO.
 4. A water-repellent film-coated article according to claim 1,wherein said water-repellent film contains silicon oxide at 70-98 molepercent (based on SiO₂), magnesium oxide and/or calcium oxide at 1-29mole percent (based on MgO and CaO), boron oxide and/or zirconium oxideat 1-29 mole percent (based on BO_(3/2) and ZrO₂) and a water-repellentgroup at 0.01-20 wt %.
 5. A water-repellent film-coated articleaccording to claim 4, wherein said water-repellent film furthercontains, in terms of mole percent, at least one of metal oxide selectedfrom the group consisting of aluminum oxide, gallium oxide, indiumoxide, scandium oxide, yttrium oxide, lanthanum oxide, cerium oxide,cobalt oxide, iron oxide, nickel oxide, copper oxide and zinc oxide at0.5-5%, based on AlO_(3/2), GaO_(3/2), InO_(3/2), ScO_(3/2), YO_(3/2),LaO_(3/2), CeO_(3/2), CoO, FeO_(3/2), NiO₂, CuO and ZnO.
 6. Awater-repellent film-coated article according to any one of claims 1 to5, wherein said water-repellent group is an alkyl group or fluoroalkylgroup.
 7. A water-repellent film-coating composition containing (A) athoroughly hydrolyzable silane compound, (B) a silane compound with awater-repellent group, (C) an acid and (D) a compound of at least one ofmetal selected from the group consisting of magnesium, calcium,strontium and boron.
 8. A water-repellent film-coating compositionaccording to claim 7 which contains said silane compound (A) at 0.01-2wt % based on SiO₂, said silane compound (B) at 0.00001-0.15 wt % basedon SiO₂, said acid at 0.001-3 N, water at 0-5 wt % and said compound (D)at a molar ratio of 0.01-0.4, based on MgO, CaO, SrO and BO_(3/2), withrespect to said silane compound (A).
 9. A water-repellent film-coatingcomposition according to claim 7 or 8 which contains an alcohol as asolvent.
 10. A water-repellent film-coating composition containing (A) athoroughly hydrolyzable silane compound or its hydrolysate at 0.01-2 wt% (based on SiO₂), (B) a silane compound with a water-repellent group at0.00001-0.15 wt % (based on SiO₂), (C) an acid at 0.001-3 N, (D-1) amagnesium and/or calcium compound at a molar ratio of 0.01-0.4, based onMgO and CaO, with respect to said silane compound (A) (based on SiO₂),(D-2) a boron and/or zirconium compound at a molar ratio of 0.01-0.4,based on BO_(3/2) and ZrO₂, with respect to said silane compound (A)(based on SiO₂), (E) a compound of at least one of metal selected fromthe group consisting of cobalt, iron, nickel, copper, aluminum, gallium,indium, scandium, yttrium, lanthanum, cerium and zinc at a molar ratioof 0-0.4, based on CoO, FeO_(3/2), NiO₂, CuO, AlO_(3/2), GaO_(3/2),InO_(3/2), ScO_(3/2), YO_(3/2), LaO_(3/2), CeO_(3/2) and ZnO, withrespect to said silane compound (A) (based on SiO₂), and (F) water at0-20 wt %.
 11. A water-repellent film-coating composition according toclaim 10 which contains an alcohol as the solvent.
 12. A water-repellentfilm-coating composition according to any one of claims 7 to 11, whereinsaid silane compound (A) is a tetraalkoxysilane or tetrachlorosilane.13. A water-repellent film-coating composition according to any one ofclaims 7 to 12, wherein said acid is hydrochloric acid, nitric acid,acetic acid, formic acid or trifluoroacetic acid.
 14. A process forpreparation of a water-repellent film-coated article, characterized byapplying a water-repellent film-coating composition according to any oneof claims 7 to 13 onto a substrate surface and drying it.
 15. A processfor preparation of a water-repellent film-coated article according toclaim 14, wherein said drying is carried out at room temperature.
 16. Aprocess for preparation of a water-repellent film-coated articleaccording to claim 14 or 15, wherein said drying is carried out in anatmosphere at 40% relative humidity or lower.
 17. A process forpreparation of a water-repellent film-coated article according to anyone of claims 14 to 16, wherein said drying is followed by heating at atemperature of from room temperature up to 300° C.
 18. A process forpreparation of a water-repellent film-coated article according to anyone of claims 14 to 16, wherein said drying is followed by heating at atemperature of from room temperature up to 150° C.